5.

INDUSTRIAL ENGINEERING
PROBLEMS & SOLUTIONS

1. Production system

1. In a Make Through System how many operators work?

Ans.: There are no operators in Make Through System. Only one tailor works
2. What is a Progressive Bundle System?
Ans.: It’s a production system where a specified number of cut parts of
garments progressively move from one workstation to next
3. What is a unit production system?
Ans.: In this production system parts of a single garment move one workstation to
next
4. In a bundle system parts of 10 shirts are bundled. How many parts are bundled
together at assembly?
a. 10 ii. 20 iii. 40 iv. 0
5. If collar marking takes 0.40 minutes when will the run stitch operator receive the
bundle of 15?
a. 1 minute ii. 6 minutes iii. 4 minutes iv. 3 minutes
6. Collar turning, point making, pressing and trimming are assigned usually to how
many operators in a sewing line?
a. 1 ii. 2 iii. 3 iv. 4
7. If collar peak turn takes 0.45 minutes in a modular system what is the waiting time
from previous operation?
a. 27 seconds
b. 270 seconds
c. 350 seconds
d. 300 seconds
8. In a PBS with 1 bundle of 10 garments, what is the time taken for cuff preparation if
there are 8 operations and each operation takes approximately 30 seconds?
a. 80 minutes
b. 1.45 hours
c. 90 minutes
d. 4000 seconds
9. In a unit system collar preparation takes 6 minutes, cuff takes 4 minutes, sleeves
require 6 minutes, front requires 7 minutes, back needs 5 minutes. What is the total
time taken for all the parts to reach assembly?
a. 0.467 hours
b. 350 minutes
c. 28 minutes
d. 1690 seconds

10. The waist band of a trouser has 3 operations which take 16 minutes together to
complete. If a bundle has 20 garments, how many bundles can be completed in a day?
 a. 1.30
b. 1.75
c. 1.50
d. 1.25
11. If the SAM of a dress is 35 minutes, in a production line using PBS, with 25
machines and bundle size 10, how much time does it take for the first completed dress
to come out?
a. 6 hours
b. 5.84 hours
c. 5.80 hours
d. 5.93 hours
12. The standard time of a ladies top is 24 minutes. The production line uses 56
machines. The cut parts move in a bundle of 20 garments. How many hours it will
take to get a bundle out of the line?
a. 10 hours
b. 8 hours
c. 6 hours
d. 12 hours
13. Button sewing a shirt takes 80 seconds. If the bundle contains 15 shirts and the
previous operation takes 30 seconds, what is the total time taken for the bundle of
shirts to get buttoned?
a. 27 ½ minutes
b. 29 minutes
c. 25 ½ minutes
d. 22 minutes
14. In a factory two dress lines are being set for loading the same style. One line follows
unit production and the other PBS. If the first operation of the dress takes 0.341
minutes and a bundle has 10 garments, when will the next operation start in both
lines?
a. unit line after 20.46 seconds and PBS after 3 minutes
b. unit line after 0.341 minute and PBS after 3.14 minutes
c. unit line after 20.40 seconds and PBS after 3.41 minutes
d. unit line after 20.46 seconds and PBS after 204.6 seconds
15. The Unit production system is faster than the PBS (Yes / No)

2. Sewing machines
1. Post bed machine is used for sewing shirts (True / False)
2. Which is the least common type of sewing machine?
a. cylinder bed
b. flat bed
c. off-the-arm
d. post-bed
3. When the feed mechanism lies below the surface it is called …. feed
4. Heavy canvas materials are stitched with ……….feed machines
a. needle b. drop c. puller d. manual
5. Walking foot walks with the fabric ( True / False)
6. Which is the most common feed type?
a. needle
b. manual
c. drop
d. puller
7. Which is the machine used extensively in a T-shirt production line?
a. Single Needle Lockstitch
b. Single Needle Chain stitch
c. Three Thread overlock
d. Three Thread flatlock
8. Treadle on the industrial sewing machines starts its operation (True / False)
9. Throat plate is also called …….plate
a. face b. needle c. cover d. ring
10. ……..moves the fabric to regulate stitch
a. needle b. feed dog c. presser foot d. shaft
11. Thread to the shuttle is carried by ……..
a. bobbin b. needle c. shaft d. hook
12. Which is the machine used in attaching sleeve to body in a knit top?
a. 2 needle feed-off-arm
b. 1 needle drop feed lockstitch
c. 3 thread overlock
d. 4 thread flatlock
13. Which type of machine bed is used for hemming the dress bottom
a. Cylinder
b. Flat
c. Post bed
d. Off-the arm
14. Which of the feeding mechanisms reduces seam slippage?
a. Needle feed
b. Drop feed
c. Walking foot
d. Manual feed
15. When sewing heavy fabrics which type of feed system is used?
a. Manual feed
b. Puller feed
c. Drop feed
d. Walking foot
16. Attachments are used to improve ……….and …………….
a. appearance …….quality
b. quality ……production
c. quantity …….capability
d. seams …….stitches
17. Which of the following is a movement of the needle bar?
a. rotary b. up-down c. forward d. cyclical
18. Bobbin is housed in the arm (True / False)
19. Differential feed is a variation of …..
 a. Manual feed
b. Drop feed
c. Puller feed
d. Needle feed
20. To sew stretch fabric differential feed machines are used. (True / False)
21. Do overlock machines use bobbin? (Yes / No)
22. Which of the following machines is used for safety stitch?
a. 2 thread overlock
b. 3 thread overlock
c. 5 thread overlock
d. 4 thread overlock
23. Yoke topstitch in a woven shirt line the preferred sewing machine is ……..
a. Single needle overlock
b. Single needle lockstitch
c. Single needle chain stitch
d. Single needle flatlock
24. Stitch type of feed-off-arm machine is not lockstitch (True / False)
25. Which of the machines consumes least thread per stitch?
a. single needle lockstitch
b. double needle lockstitch
c. single thread overlock
d. single thread chain stitch
3. Sewing cycle time, Basic Process Time and Standard Allowance Time
1. The sewing cycle of an operator in a production line was recorded. The pre-sewing
average time of the operators was 0.85 minute. Sewing time was 0.55 minute and
post-sewing time was 0.75 minute. What was the cycle time?
a. 2.15 minutes
b. 2.25 minutes
c. 2.10 minutes
d. 2.05 minutes
2. The cycle time of 3 operators for the same operation were recorded as below:
a. Pre-sewing time of 3 operators (minutes) – 0.15, 0.16, 0.20 0.51
b. Sewing time of 3 operators (minutes) – 0.14, 0.14, 0.16 0.44
c. Post-sewing time of 3 operators (minutes) -0.13, 0.12, 0.14 0.39
What is the average cycle time of the operation?
1. 0.446
2. 0.464
3. 0.444
4. 0.454

3. The observed times for a presser foot and needle down movement are recorded 4
times (seconds) as – 1.25, 1.17, 1.19 and 1.20. Find the Basic Time.
a. 1.204
b. 1.202
c. 1.201
d. 1.203
4. Times of 5 operators were recorded for thread cutting operation after sewing in a line.
The observed times (seconds) recorded were –
1.60
2.01
2.45
2.15
2.25
Calculate the basic time if observed rating is 75 and standard rating 100
a. 1.570
b. 1.569
c. 1.565
d. 1.566
5. Time was observed and recorded for sewing front placket of 30” length of a shirt by 3
operators (minutes) as below:
a. 1.65
b. 1.85
c. 1.75
What is the basic time if the observed rating is 80 and standard rating 100?
a. 1.55
b. 1.40
c. 1.45
d. 1.44
6. A collar run stitch marking took 1.05, 1.15, 1.18, 1.24, 1.28 minutes for an operator
on 5 different observations. If the observed rating is 90 and standard rating 100 what
is the basic time for the run stitch marking?
a. 1.052
b. 1.062
c. 1.045
d. 1.043
7. A yoke attachment to back of a ladies shirt by 5 operators was observed and the times
were recorded in seconds as – 34.05, 39.09, 39.00, 40.11, and 40.10. Calculate the
basic time if observed rating is 80 and standard rating is 100.
a. 31.10
b. 30.92
c. 30.85
d. 30.89

8. Observed times in minutes for side seam closure of men’s shirt using feed off arm
with folder are – 1.18, 1.17, 1.20, 1.19, and1.21. The observed rating is 80 and the
standard rating 100. Find the basic time of the operation?
a. 0.952
b. 1.102
c. 0.985
d. 0.955
9. Observed timing in minutes of side seam closure using double needle machine with
folder are – 1.55, 1.75, 1.65, 1.85 and 2.01.Find its BPT if OR and SR are 75 and 100
respectively.
a. 1.151
b. 1.215
c. 1.321
d. 1.322
10. A production line layout was changed with operators picking parts for sewing with
right hand. Earlier layout was designed with operators picking with left hand.
Observation of the three pick up operation times (seconds) are recorded as –
a. Pick left hand – 1.68 Pick right hand – 1.45
b. Pick left hand – 1.72 Pick right hand – 1.42
c. Pick left hand – 1.70 Pick right hand – 1.40
Find the difference in basic time for left and right hand operation if the OR and SR
are 80 and 100 respectively.
1. left 1.36, right 1.38 and difference 0.02
2. left 1.38, right 1.42 and difference 0.04
3. left 1.35, right 1.38 and difference 0.03
4. left 1.39, right 1.42 and difference 0.02
11. The basic time of a collar run stitch operation is 74 seconds. Calculate the standard
allowance minute if personal allowance is 10%, machine allowance is 5%, and
contingency allowance is 2%.
a. 80.50
b. 86.58
c. 84.35
d. 86.45
12. A factory works with the allowances – personal 12%, machine 4%, contingency 3%.
If the basic time of a side seam operation of a dress is calculated as 1.06 minutes,
what is the SAM for the operation?
a. 1.32
b. 1.36
c. 1.26
d. 1.22
13. A jacket shell has basic time of 27 minutes and the basic time of lining making is 19
minutes. The final assembly requires basic time of 15 minutes. If personal allowance
is 14%, machine allowance is 3% and contingency allowance is 2%, what is the SAM
of the jacket?
a. 67.20
b. 72.59
c. 70.40
d. 73.49
14. A long coat hemming by 3 operators was observed and times recorded as 74.00,
85.00 and 79.00 seconds. If the observed and standard ratings are 80 and 100 and
allowances together are 18%. What is the SAM for the operation?
a. 74.85
b. 74.88
c. 74.89
d. 74.86
15. A pair of trousers needs 34 machines for production. Fly preparation takes 3.54
minutes. Outseam takes 2.54 minute and inseam needs 3.58 minute, waist band
preparation takes 3.05 minutes and attachment takes 3.08 minutes. If the total basic
time is 18.00 minutes what is the time taken for zip attachment?
a. 2.25
b. 2.21
c. 2.29
d. 2.23
16. The standard time for collar run stitch is 0.72 minute. Number of operators engaged is
1. What is the pitch time?
a. 0.75
b. 0.72
c. 0.74
d. 0.71
17. The back preparation of a shirt needs 4 operators. The SAM of the 5 operations –
label attach: 0.412, back pleat: 0.471, back yoke attach: 0.553, back yoke edge stitch:
0.412 and back yoke trim: 0.294. Calculate the pitch time.
a. 0.433
b. 0.428
c. 0.426
d. 0.429
18. A production supervisor sets a target for dress hemming as 1000 pieces per day. What
is the pitch time?
a. 2.10
b. 2.08
c. 2.11
d. 2.09
19. Target for trousers production is set as 800 units per day on a production line of 42
machines. SAM for the trousers is 24 minutes. Calculate the pitch time using target
and operations.
a. 0.60
b. 0.57
c. 0.55
d. 0.59
20. A shirt assembly SAM is 13.511. It has 18 operations. What is its PT?
a. 0.73
b. 0.70
c. 0.75
d. 0.78
4. Line balancing and WIP
1. Find the configuration efficiency of a ladies dress production line if the bottleneck
operation time is 126 seconds and pitch time is 60 seconds.
a. 45.60
b. 47.62
c. 44.62
d. 46.60
2. If the actual production of a shirt in production line of 56 machines is 1010 per day of
8 hours, find the bottleneck operation time.
a. 0.457
b. 0.475
c. 0.574
d. 0.745
3. Find the pitch time of a dress if configuration efficiency of the production line is 75%
and the bottleneck operation is 60 seconds.
a. 50
b. 45
c. 40
d. 55
4. The configuration efficiency of a skirt production line is 90% and the pitch time of
the line is 28 seconds, find the bottleneck operation time.
a. 0.30
b. 0.31
c. 0.35
d. 0.32
5. Find the Bottleneck Operation Process Time or Bn. PT in a production line if the
actual production is 650 garments and the work hours available are 8.
a. 0.738
b. 0.750
c. 0.710
d. 0.735
6. The pitch time of a dress is 0.59 and the bottleneck process time is 0.78. What is the
line efficiency?
a. 55.54%
b. 75.64%
c. 85.45%
d. 65.75%
7. The bottleneck process time of a shirt is 0.76 and efficiency of the line is 0.546, what
is the pitch time?
a. 0.391
b. 0.415
c. 0.421
d. 0.405
8. If the pitch time of a skirt line is 0.38 and line efficiency 0.65 is what is its bottle neck
process time?
a. 1.25
b. 1.71
c. 156
d. 1.75
9. Find the WIP in a sewing line of shirts given the cuttings loaded and finished
garments moved are 1000 and 850 respectively.
a. 185
b. 150
c. 250
d. 100
10. If the WIP of a skirt line is 125 and the garments moved to finishing section are 600,
what is the quantity loaded in the line?
a. 800
b. 725
c. 475
d. 400
11. If the production line of jackets delivers 400 per day, what is the bottleneck process
time?
a. 1.50 minutes
b. 1.20 minutes
c. 1.30 minutes
d. 1.10 minutes
12. The target set for a production line of suits is 550 units per day, what is the pitch time
of the line?
a. 0.30 minutes
b. 0.87 minutes
c. 0.11 minutes
d. 0.14 minutes
13. Find the bottleneck process time for the above suit line with 350 units production per
day?
a. 1.50 minutes
b. 1.37 minutes
c. 1.62 minutes
d. 1.64 minutes
14. What is the line efficiency of the above suit line with PT 0.87 minutes and Bn. PT as
1.37
a. 65.35%
b. 63.50%
c. 62.50%
d. 65.25%
 15. If the number of cuttings of a skirt received is 1000 and the feeding helper loaded all
the cuttings what must be quantity finished having zero WIP in the line?
a. 900
b. 1000
c. 0
d. 999
16. In a suit line the jacket WIP is 50 and units loaded were 400 and the pants cuttings
loaded were 400 and output was 325. Find the output of jackets and WIP of pants.
a. 300 jackets and 50 pants
b. 350 jackets and 75 pants
c. 325 jackets and 50 pants
d. 50 jackets and 75 pants
17. A dress has embroidery work of 15.25 SAM. Dress sewing SAM is 40 minutes. For a
production of 800 dresses, 350 are loaded with embroidery in a production line of 24
machines. The balance is in embroidery work loaded on a 20 head embroidery
machine. What is the WIP in the sewing and embroidery and how many days are
required to complete the dress production?
a. WIP is 75 and 2 days to complete dress production
b. WIP is 62 and 3 days to complete dress production
c. WIP is 62 and 2 days to complete dress production
d. WIP is 60 and 2 days to complete dress production
18. A jacket was loaded in a production line of 40 machines. The SAM of the jacket is 32
minutes. If the actual out put is 550, find the PT, Bn.PT and configuration efficiency
of the line.
Ans: PT of jacket – 0.8, Bn.PT of jacket - 0.87, Configuration efficiency –
92%
19. A skirt is loaded in a production line of 35 machines. If the SAM of the garment is 28
minutes and actual production is 450, find the target, PT and configuration efficiency.
Ans: Target - 600, PT – 0.8, Configuration Efficiency – 75%
20. Find the Bn.PT and configuration efficiency of a shirt line given 0.26 PT and actual
production as 720 per day.
Ans: Bn.PT – 0.67, Configuration Efficiency - 133%
5. Productivity, Production Loss and Lost Time
1. A garment factory has a production capacity of 1200 units per day. Style change in
production occurs 4 times in a month and work is affected for 8 days. Calculate the
loss in production due to style change?
1. 9000
2. 9600
3. 8900
4. 9400
2. A factory produces 200 shirts on a line of 15 machines per day. What is the
productivity of the line?
1. 50.00%
2. 41.67%
3. 40.65%
4. 42.00%
3. Needle change on a sewing machine requires 1.15 minutes. On an average 5 needles
break in a sewing line of 50 machines and the time consumed is 15.75 minutes. There
are 6 lines in a factory. What is the time loss due to needle change?
1. 1.60 hours
2. 1.58 hours
3. 1.55 hours
4. 1.59 hours
4. The production capacity of a factory of 800 machines was given as 7500 shirts per
day. Absenteeism in the factory is averaged at 18% per month. Calculate the loss in
production?
1. 35100
2. 33500
3. 35000
4. 31500
5. A production line has 56 machines with a daily capacity 800 garments. Three
machines required repairs on a day and it took 2 hours repair them. Production loss
due to repair was 3% per hour. What is the total production loss?
1. 20
2. 24
3. 26
4. 22
6. A dress sewing line has with 30 SNLS and 2 DNLS, 2 FOA, 2 collar turn and 2 waist
band machines. Daily production capacity of this configuration was 760 garments.
The 24 minute SAM of the garment increased to 34 minutes as 3 of the machines
broke down. Calculate the daily loss in production.
1. 250
2. 270
3. 290
4. 240
7. A garment factory has 1200 machines in 20 lines. The installed production capacity is
24000 garments per day. Calculate actual production based on the following losses:
a. Absenteeism 10%
b. Idle time 4%
c. Needle breakage & other repairs 4%
1. 19460
2. 19680
3. 19560
4. 19690
8. In a production line of 60 machines a garment style with a SAM of 34 minutes was
loaded. Due to various issues the waiting time in the line was recorded as 4% per day
for 4 days from the third day. What is the production loss for 4 days in the line?
1. 104
2. 100
3. 110
 4. 112
9. A production line with 50 machines was giving an output of 900 garments. However
due to absenteeism under skilled operators were placed on the line for 5 days
resulting in poor quality and reduction in output. Loss due to quality was 22% of the
daily production. What is the daily production for the 5 days?
1. 695
2. 700
3. 702
4. 705
10. The SAM of a shirt is 26 minutes and actual production is 900 pieces per day and
number of operators in the line was 56; what is the loss in production?
1. 150
2. 134
3. 144
4. 154
11. If the basic time of frock is 42 minutes and allowances are 15%, actual production
being 540 pieces per day on a sewing line of 48 machines, what is the daily
productivity and production target?
1. 115.50% and 400
2. 112.5% and 480
3. 120.5% and 500
4. 110.25% and 550
12. A formal trouser has one welt pocket and two side pockets. The pitch time for the
welt pocket is 2 minutes. What is the production target per day?
1. 260
2. 960
3. 240
4. 120
13. A blazer has 4 welt pockets of which 2 have flaps. Each welt pocket SAM is 1.40
minutes. Pocket flap SAM is 0.20 minutes. What will be the daily production?
1. 120
2. 80
3. 170
4. 150
14. There are 3 eyelet buttonholes on the front of the jacket, 2 on each sleeve and 2 on
trousers waist band and 2 on the welt pockets. Standard time of each buttonhole is
0.35 minutes. The standard allowance is 15%. Calculate the SAM and productivity
per day if 2 machines work?
1. 235
2. 265
3. 255
4. 245
15. A sewing line that was making ladies dresses has a target of 700 units per day. Of the
50 machines if 10 are attached with folders to improve the productivity by 20%, find
the SAM of the garment.
1. 41.14
2. 27.42
3. 34.28
4. 27.62
16. An embroidery design on a dress takes 4 minutes to stitch. If 75 dresses are
embroidered in a day what is the productivity?
1. 65.5%
2. 62.5%
3. 60.5%
4. 61.5%
17. In a production line of trousers, one bartack machine was sewing 9 bartack stitches
per garment in 1.50 minutes. However, after 6 hours of production the machine broke
down. Calculate the production loss?
1. 120
2. 160
3. 140
4. 159
18. When a buttonhole machine broke down, production target of 800 garments stopped
by 25%. What was the production loss%?
1. 3%
2. 2%
3. 5%
4. 6%
19. If the SAM of a skirt is 15 minutes on a production line of 22 machines and the actual
production is 500, what is the production loss%
1. 2.25%
2. 2.04%
3. 2.15%
4. 2.20%
20. A pocket welting machine can welt 318 pockets in a day. However, due to non-
availability of fusing it has produced only 260 pockets. What is the productivity?
1. 54%
2. 56%
3. 58%
4. 59%
21. A production line of 40 operators in an 8 hour shift produce 780 garments with a
SAM of 24 minutes. What is the time lost per garment?
a. 96.5
b. 97.5
c. 94.5
d. 99.5
 22. SAM of a shirt is 32 minutes and the production line has 60 machines. However, 4
machines had to be replaced interrupting production and the output was 800 shirts.
Calculate the lost time per shirt.
e. 160.30minutes
f. 155.50 minutes
g. 150.45minutes
h. 145.55minutes
23. A collar attachment operation was held up for quality in the previous operation. The
SAM of the operation was 0.78 minutes. What is the lost time of the operation?
i. 0
j. 100
k. 99.99
l. 95
24. Sleeve cuff turning operation takes 1.05 standard minutes. Due to machine repair
production was only 324. Calculate the lost time.
m. 71%
n. 75%
o. 83%
p. 84%
25. If the standard time of a buttoning operation is 0.26 and the actual output is 325
pieces find the time lost?
q. 18.00%
r. 17.60%
s. 17.50%
t. 19.00%
6. Utilisation and Incentive schemes
1. An automatic cutting machine was capable of cutting 40,000 shirts per day. However,
it was cutting only 30,000 pieces per day. Find the utilisation of the machine?
a. 25%
b. 55%
c. 75%
d. 65%
2. If production per day of a sewing line was 500 units, the utilisation was improved
with new production practices and the revised daily production was 615 units. Find
the increase in utilisation?
a. 25%
b. 23%
c. 20%
d. 100%
3. A fashion shirt production line was using 86 machines to produce 740 units a day.
Through method study with same number of machines output increased to 1000.
What is the increase in utilisation?
a. 50%
b. 35%
c. 45%
d. 40%
4 The standard time of a dress was 36 minutes. The production line was laid out with
45 machines. However, the actual output was only 525 dresses par day. Find the
maximum capacity and the utilisation?
(1) 75.0%
(2) 87.5%
(3) 85.5%
(4) 78.5%
5 In a garment factory incentive was given based on the number of pieces produced
over the set target at the rate of Rs. 50 for every 10 pieces produced per hour during
the working hours. If a production line was given a target of 1000 shirts per day and
the line earned incentive of Rs. 2000, what was the total production of the day?
i) 1200
ii) 1400
iii) 1600
iv) 1500
6 In a jacket line target per day is 640 pieces with a standard time of 36 minutes and 48
machines. But the actual production per day is 450 pieces. In order to increase
production an incentive of Rs.5 per garment is given to each operator and the daily
production increased by 30%. What is the loss in production and the cost of total
incentive given?
i) 85% and Rs.650
ii) 70% and Rs.675
iii) 75% and Rs.600
iv) 65% and Rs.550
7 The shirt line was producing 750 garments per day. To increase the production
incentive of Rs.3 was given per piece to A grade operators, Rs. 2.50 per piece to B
grade operators, and Rs.2 per piece to C grade operator. The production line employs
8 A grade, 17 B grade and 20 C grade operators and the production improved by
40%. What is the incentive total given to all the operators?
i) 31500, ii) 31950, iii) 31450, iv) 31790
8 The dress line production target was 850 units per day and the actual production was
650 units. An incentive of Rs. 4 was given to the line to improve the production by
25%. What is the production efficiency before incentive and utilisation after
incentive?
i) Production efficiency = 30.77% and utilisation = 77.74%
ii) Production efficiency = 76.47% and utilisation = 95.59%
iii) Production efficiency = 70.47% and utilisation = 90.59%
iv) Production efficiency = 76.50% and utilisation = 95.59%
9 Find the average output of a skirt line given production target is 1000 units and
utilisation of the line is 50%?
a 500, b. 800, c. 600, d. 700
10 Find the production target of a trouser line if its average output is 800 and utilisation
is 75%?
a 1066, b. 600, c. 1200, d. 700
11 Find the line utilisation if a skirt line target was 800 units and production was as
follows:
a 1st day – 400 units, 2nd day – 400 units, 3rd day – 500 units, 4th day – 600 units
b 5th day – 600 units
i) 62.5
ii) 60.5
iii) 65.5
iv) 63.5
12 Find the production target of a jacket line if the production efficiency is 65% and the
daily production is 600 units?
a 900
b 923
c 950
d 910
13 If the daily production is 1000 and the production efficiency is 75%, what is the
production target of the line?
a 1323
b 1333
c 1353
d 1343
14 What is the utilisation and production efficiency of a dress line if the average out put
for a month is 500 and daily output on a day was 800 with the target being 600?
Ans. Utilisation = 83.33%; production efficiency =133.33
15. Find the production efficiency if the SAM of jeans was 24 minutes and actual daily
production was 750 units?
(a) 95.50
(b) 93.75
(c) 94.75
(d) 96.75
16. Find the utilisation of a T-shirt production line if the SAM is 12 minutes with 14
machines and the average production is 600 units?
(a) 100
(b) 107
(c) 108
(d) 106
17. A factory offers incentives based on productivity. Three production lines each of 54
machines are loaded with shirt, trousers and skirt with a SAM of 28, 24 and 20
minutes. The actual production of each line is 750, 1000 and 950. What is the
productivity of each line?
Ans: Productivity of shirt line – 81%, trouser line – 92.59%, skirt line – 73.30%
18. A trousers production line has a productivity of 85%. What is the actual production?
(a) 400
(b) 408
(c) 410
(d) 405
 19. If the SAM of a jacket is 42 minutes in a production line of 60 machines, and the
actual production is 500 units, what is the production efficiency?
(a) 75.25
(b) 75.75
(c) 75.50
(d) 75.45
20. Incentive scheme in a company is based on line efficiency at Rs.100 per day per
person for the number of days it is maintained. What does each operator get in a line
of 45 machines if the efficiency is maintained at 85% for one month?
(a) Rs. 2400
(b) Rs. 2600
(c) Rs. 2800
(d) Rs. 2200

7. Production capacity
1. A garment unit has 2 production lines of 40 machines each. How many machine
hours are available per day?
a. 700
b. 640
c. 500
d. 680
2. A factory has 6 production lines of 45 machines each. If the SAM of a shirt is 30
minutes, how many men’s shirts that can be produced in one hour?
a. 580
b. 540
c. 500
d. 550
3. A dedicated shirt factory has 180 machines. The average basic time of a shirt is 28
minutes and the standard allowance is 25% of the BT. Find the daily production
capacity of the factory?
a. 2500
b. 2520
c. 2525
d. 2575
4. A factory has 4 lines of 46 machines. If the standard time of the shirt is 28 minutes
what is its daily production capacity?
a. 3000
b. 3154
c. 3254
d. 3054
5. A trouser unit has set up a line of 25 specialised machines for production. It accepts
an order to produce 15,000 units per month. Calculate its daily production capacity.
a. 500
b. 575
c. 550
d. 577
6. A trouser factory with 35 machines has a production capacity to make 700 formal
trousers per day. If the factory efficiency is 55% what is its daily production?
a. 350
b. 385
c. 400
d. 375
7. In a company three divisions produce casual wear, formal wear and women’s wear.
The number of machines in each division is 250. The SAM women’s wear is 25
minutes, casual wear is 30 minutes, and formal wear is 35 minutes. What is total
production capacity of the company?
a. 12229
b. 12359
c. 12225
d. 12469
8. A suit factory has 2 sewing lines of 50 machines one dedicated for jacket and the
other for trousers. The standard times of jacket and trouser are 45 minutes and 25
minutes respectively. What is the daily production capacity of jackets and trousers?
a. 530 and 960
b. 550 and 975
c. 530 and 940
d. 525 and 900
9. A shirt factory with 2 production lines of 50 machines each produces 1600 units
daily. By adding 2 machines each for collar and cuff turning and trimming the
production will increase by 6 shirts. What is the daily output per machine before
turning and trimming machines added to the lines?
a. 20
b. 28
c. 16
d. 24
10. A trouser line in a factory was producing 840 units per day on 34 machines. The line
was using 4 machines for welt pocket operation which were replaced with automatic
welt machine and the standard time improved by 15%. What is the revised
production?
a. 885
b. 882
c. 890
d. 887
11. A collar turning and pressing machine can deliver per day 2000 collars. Find its
production capacity per month?
a. 50,000
b. 52,000
c. 49,000
d. 51,000
12. A production line had regular 54 SNLS machines which were producing 900
garments per day. 15 of the machines were replaced with programmable UBT
 machines. Production of the line increased 1000 units per day. What is the percentage
increase due to the new machines?
a. 11.15
b. 11.13
c. 11.11
d. 11.10
13. A regular button stitch machine stitches 150 buttons per day. It was fitted with
programmable button feeding system and the productivity increased by 20%. Find the
new production capacity?
a. 190
b. 180
c. 200
d. 170
14. A garment factory has a production capacity to produce 17,000 shirts per week. What
is its daily production?
a. 2838
b. 2834
c. 2836
d. 2835
15. In a factory there are 3 production lines. Two of these lines are operated by women
while the third is operated by men. Daily production of the women’s lines is 640
pieces each and the men’s line produces 700 pieces with absenteeism of 10% in the
women’s lines and 5% in men’s line. What will be the total production capacity of the
three lines combined if the attendance is full?
a. 1450
b. 1500
c. 1439
d. 1449
16. A sewing line produces 800 garments a day. There is scope to improve the production
by 200 garments if work aids are used. Find the percentage increase in production
capacity?
a. 30
b. 25
c. 20
d. 28
17. A factory had 7 sewing lines operating with 86 machines each. A lean consultant
changed the layout by reducing the number of machines per line to 43 without
reduction in production capacity of 800 units per line. What is the increase in
production capacity?
a. 40%
b. 50%
c. 30%
d. 60%
 18. 5 Sewing lines in a garment factory with 54 machines each work with 55%
efficiency. The average standard time of a garment is 24 minutes. What is the
installed production capacity of the sewing lines?
a. 5500
b. 5400
c. 5600
d. 5200
19. Installed capacity of sewing line is 900 garments per day. Productivity of the line is
85%. What is the actual production of the line?
a. 750
b. 765
c. 755
d. 760
20. A production line of skirts ha 36 machines. The standard time of a skirt is 26.12
minutes. What is the production capacity of the line?
a. 660
b. 662
c. 664
d. 668
9. Production Planning
1. An order quantity of 60,000 shirts is received. The SAM of the shirt is 22 mnts. The
factory efficiency factor is 55. The order needs to be delivered in 60 days. How many
machines are required?
i. 75
ii. 71
iii. 70
iv. 72
2. Purchase order for 25,000 shirts is received. The SAM of the shirt is 24 minutes. The
factory efficiency factor is 45%. The order needs to be delivered in 60 days. What
will be the number of machines required in the production line?
i. 30
ii. 31
iii. 32
iv. 34
3. Plan a production line for a dress that has embroidery. The order quantity is 6000
dresses and embroidery production per day is 250 units and SAM of the dress is 34
minutes.
i. 24
ii. 18
iii. 22
iv. 26
4. Merchandiser accepts an order for 2000 dozens of shirts with a SAM of 28 minutes.
How many days are needed if the production line of 60 machines is assigned?
i. 26
ii. 24
iii. 20
iv. 22
5. A trouser has a work content of 20 minutes. The production line has 24 machines.
How many days must be planned to complete an order of 6000 units?
i. 14
ii. 10
iii. 16
iv. 12
6. If a production line has a target of 800 shirts with an efficiency of 85%, how many
days are needed to complete an order of 600 dozens?
i. 11
ii. 10
iii. 12
iv. 9
7. If the utilisation of a production line is 55% against a capacity of 1200, how many
lines need to be added to complete 50% of an order of 100,000?
i. 76
ii. 74
iii. 75
iv. 77
8. Three Pos in a company have same date of production completion. But two of the
orders receive materials late by 10 days. The only PO with materials in-house will
complete production by this time. One of the PO’s has 8000 to produce with a SAM
of 24 while the other has 10,000 units with a SAM of 20. How many machines are
required to complete both the orders in 15 days?
i. 26
ii. 27
iii. 30
iv. 25
9. If a garment has softener wash of a total 90 minutes per a load of 60 garments and the
total quantity to be washed is 6000, how many days will it take to complete the wash
programme?
i. 22
ii. 18
iii. 19
iv. 20
10. If a dress has a standard time of 40 minutes and the total order of 4000 units to be
shipped in 20 days, how many lines are required and with how many machines per
line?
i. 18 ii. 17 iii. 19 iv. 20
11. Nike Bermuda takes 18 standard minutes. Factory efficiency is 55% and the order
quantity is 16000. Each production line in the factory has 42 machines. How many
lines are needed to complete the order in 15 days?
i. 2
ii. 1
iii. 4
iv. 3
12. A Wet Seal girls’ top has a SAM of 20 minutes. Garment embroidery takes 3
minutes. The fabric has Lycra and has to be washed before cutting which takes 1 day.
If the total order is 10000 garments, how many sewing lines of 36 machines are
required to complete the order in 25 days?
i. Embroidery on 20 head machine takes – 3 days
ii. Washing of fabric takes - 1 day
iii. Balance days remaining for production – 25 – 4 = 21 days
iv. Target production per day = 10,000 / 21 = 476 units
v. Production per machine = 480 / 20 = 24 units
vi. Total production per day = 24 x 36 = 864 units
vii. No. of lines required =1
13. How is production priority planned for 4 lines with 6 styles each having a SAM of 22,
26, 30, 32, 18 and 20 minutes?
Ans: In descending order of SAM
14. Plan a production of jeans with a SAM of 24 minutes, enzyme wash of 2 hours per
load of 40 garments, considering that the total lead time is 60 days. Fabric and trims
delivery takes 25 days and the order quantity is 12000.
Ans: 17 machine production line, with 3 washing units to complete
production in 35 days
15. Find the time required to deliver an order quantity of 24000 shirts with a SAM of 28
minutes and 56 machines.
i. 26 days
ii. 25 days
iii. 23 days
iv. 24 days
16. How many machines are required to produce 2000 shirts with a standard time of 26
minutes in 5 days?
i. 20
ii. 22
iii. 24
iv. 26
17. If the SAM of a dress is 32 minutes and 46 machines are in the production line, how
many dresses can be produced in 15 days?
i. 10550
ii. 10450
iii. 10350
iv. 10250
 18. In a multi product unit with an overall efficiency of 60%, how many shirts, skirts,
shorts can be produced with a SAM of 28, 22 and 24 minutes on two lines of 56
machines each in 10 days?
i. SAM of shirt, skirt and shorts with 60% efficiency = 44.8 35.2 38.4
ii. Average number of machines per style = 37
iii. Daily production per machine by shirt, skirt, shorts = 11, 14, 13
iv. Production in 10 days by shirt, skirt , shorts = 4070, 5180, 4810
19. Plan the production of a factory of 2 lines of 60 machines each with allotment of
capacity for production with standard times and quantities of orders received jacket,
pants, and shirts as 42, 26 and 28 minutes and quantities 6000, 12000 and 18000.
Production time available is 30 days.
i. Jacket on 1 line with daily production 660 units for 9 days
ii. Pants on 1 line with daily production 1080 units for 11 days
iii. Shirts on 2 line after jacket and pants production is completed with
daily production of 1020 units for 9 days
20. If materials for all the styles for production are received, the order quantities being
2000, 3500 and 5000 of ladies shirts, plan their production given – SAM of each style
as 34, 28 and 26 minutes on 1 production line of 56 machines each for delivery in 15
days.
i. 3 days for production of 2000 shirts
ii. 4 days for production of 3500 shirts
iii. 5 days for production of 5000 shirts

10.Production costing
1. The sewing section in a factory has 4 lines of 60 machines. The average salary of an
operator is Rs.6000 per month. What is the minute cost?
(a) 125.38
(b) 115.38
(c) 120.38
(d) 122.38
2. Sewing operators in a factory are graded as per their experience and skill. Grade A
operators receive a salary of Rs.10,000, grade B get Rs. 8000, Grade C get Rs.6000
and Grade D get Rs.4500. In a sewing line of shirts 56 machines are employed. The
line has 8 Grade A operators, 16 Grade B operators, 20 Grade C operators and the
remaining are Grade D operators. What are the total wages per month? Calculate the
minute cost of the line.
Ans.: Total wages per month = Rs.382000
Minute Cost of line = Rs.30.60
3. A production line of men’s shirts employs 60 operators. Average wages per head are
Rs.8,500 per month. 50% of the operators work overtime for 2 days in a week for 2
hours at twice the hourly rate. What is the production cost per minute?
(a) Rs.40.00
(b) Rs.41.00
(c) Rs.42.00
(d) Rs.43.00
4. In a garment factory salaries of sewing operators cost per month Rs.50,000,000.
There are 800 machines in the sewing lines. Other supporting departments such as
merchandising, fabrics, cutting, finance etc., cost in salaries 1,00,000,000. What is the
making cost of a garment with SAM of 30 minutes?
(a) Rs. 430.72
(b) Rs. 450.72
(c) Rs.452.72
(d) Rs. 451.72
5. In a garment manufacturing unit, there are 5 sewing lines of 60 machines each and
300 operators and 25 helpers work in the section. Cutting section has 1 CAD-CAM
and 2 vertical cutting machines supported by bundling, packing and fusing helpers.
Fabric inspection and store employs 25 helpers and 2 managers. Sewing room
expenses are Rs.35,00,000 per month. Cutting section pays Rs.20,00,000 and fabric
stores pays Rs.10,00,000 per month. What are the total expenses and what is the
minute cost per machine?
Ans.: Total expenses of the manufacturing unit = Rs.65,00,000.
Machine cost per minute = Rs.1.74
6. Electricity charges in a garment unit are Rs.50,000 per month and expenses towards
water are Rs. 8,000 per month. Salaries and wages per month of sewing section are
Rs.12,00,000 and that of other departments are Rs.50,00,000. Annual depreciation on
machinery is Rs.6,00,000. What is the minute cost of the expenses?
(a) Rs.500.45
(b) Rs.505.45
(c) Rs.495.45
(d) Rs.510.45
7. The minute cost of machines is Rs.2.90. What is the cost of the making of a shirt if its
SAM is 24 minutes?
(a) Rs.70.60
(b) Rs.69.60
(c) Rs.60.60
(d) Rs.66.60
8. 1000 shirts are produced in a day on a sewing line of 40 machines. Expenses of the
line are Rs.320000. What is the cost of making one shirt?
(a) Rs.350
(b) Rs.320
(c) Rs.330
(d) Rs.340
9. If a shirt takes 42.66 SAM, what will be its making cost given minute cost is Rs.0.96
(a) Rs.42.00
(b) Rs.41.95
(c) Rs.40.95
(d) Rs.40.59
10. The expenses of sewing section in a company are Rs. 102,555,375 per month.
Calculate the cost per minute.
Ans.: Cost per minute of the sewing line = Rs. 8217.58
11. A garment company has 8 production lines. Number of operators in each line are 56.
The average salary per month of an operator is Rs.4,200. What is the minute cost of
the company?
(a) Rs.150.70
(b) Rs.150.77
(c) Rs.150.75
(d) Rs.150.73
12. A dress has a SAM of 32 minutes. The minute cost of the company is Rs.5.50. What
is the cost of making of the dress?
(a) Cost of making of the dress = Rs.176.00
13. The monthly expenses of a sewing line are – salaries –Rs.2,50,000; electricity –
Rs.4,000; rent – Rs.5000; employee benefits and incentives – Rs.1,25,000; needles
and maintenance – Rs.25,000; other expenses – Rs.30,000. Calculate the production
cost of a suit jacket with a SAM of 38 minutes.
(a) Rs.1335.70
(b) Rs.1336.40
(c) Rs.1336.70
(d) Rs.1337.60
14. What is the cost of making of a dress if its SAM is 35 minutes, monthly expenses are
Rs. 6,000,000. There are 4 sewing lines each line having 40 machines?
(a) Rs.100
(b) Rs.110
(c) Rs.105
(d) Rs.115
15. A trouser takes 22 minutes in production with 36 machines. Annual expenses of the
company are Rs.50,000,000 with 7 sewing lines 4 of which have 56 machines and the
rest 36 machines. Find the cost of making of trouser?
Ans.: Expenses per day = 50,000,000 / 12 x 26 = Rs. 160256.41
Total number of machines = (4x56) + (3x36) = 332
Daily expenses per machine = Rs.160256.41 / 332 = Rs.482.70
Time required for 1 trouser = 22 minutes
Number of minutes in a day = 8hrs x 60mnts = 480 mnts
Trousers produced per day by one machine = 480 / 22 = 22 nos.
Cost of making of a trouser = Rs.482.70 / 22 = Rs.21.94

16. A coordinate suit has a jacket and skirt with 42 and 18 minutes SAM. Minute cost of
the company is Rs. 4.25. If the order quantity is 2400 suits what is the total cost of
making?
(a) Rs.6,25,000
(b) Rs.6,12,000
(c) Rs.6,10,200
(d) Rs.6, 20,500
17. If the cost of making of a shirt is Rs.120 and the SAM is 32 minutes, find the cost per
minute?
a. Rs. 3.75 b. 4.25 c. 3.50 d. 3.25
 18. The total expenses of a company are Rs.150,000,000 per month with 25 sewing lines
each with 58 machines. Its daily production capacity is 26,000 garments. What is the
average SAM of a garment and what is its cost of making?
Ans.: Total expenses per day = Rs.150000000 / 26 = Rs. 5,769,230.77
Daily production capacity = 26,000
Making cost per garment = Rs.221.89
Total number of machines = 25 x 58 = 1450
Daily production per machine = 26,000 / 1450 = 18 units
Average SAM of a garment = 8 hrs x 60 mnts = 480 mnts / 18 = 26.67 mnts

19. Find the minute cost of a company which has 1200 machines and its annual expenses
are Rs.16,00,00,000
(a) Rs.1.00
(b) Rs.2.10
(c) Rs.0.89
(d) Rs.0.76
20. What is the cost of making of a shirt, pant, skirt and dress with SAM of 28, 21, 18
and 32 and the minute cost is Rs. 4.25?
(a) Rs.120, Rs.89.25, Rs.76.00, Rs.136.00
(b) Rs.119, Rs.90.25, Rs.76.50, Rs.135.00
(c) Rs.119, Rs.89.25, Rs.76.50, Rs.136.00
(d) Rs.129, Rs.89.55, Rs.76.50, Rs.136.00

10.Thread calculation
1. The total length of lockstitch seams in a shirt is 5 meters. Thread usage ratio is 2.5
with needle and looper thread percentage being 50. Calculate the thread consumption
if seams have standard stitches?
(i) 13.25 meters
(ii) 13.75 meters
(iii) 13.50 meters
(iv)13.65 meters
2. In a dress class 301 and 504 stitches are used. Total lockstitch seams length is 4
meters and overlock seams measure 2.5 meters. Using the thread consumption ratio,
calculate the total thread required for one dress.
(i) 50.00 meters
(ii) 49.50 meters
(iii) 45.90 meters
(iv)49.90 meters
3. A jacket has class 301 and 516 stitches totaling 5 meters and 3 meters. Find the thread
consumption?
(i) 120.00 meters
(ii) 118.25 meters
(iii) 124.25 meters
(iv)122.35 meters
4. In a pant there are 301, 101 and 504 class stitches. Total length of lockstitch seams is
4 meters, chain stitch seams total 2 meters and overlock seams are 4 meters. Calculate
the total thread required?
(a) 55.50 meters
(b) 50.60 meters
(c) 54.55 meters
(d) 50.50 meters
5. A 2-piece swimwear has class 605 seam of total length 1.5 meters and class 602 seam
of 2.75 meters. Find the thread consumption.
(a) 120.85 meters
(b) 121.82 meters
(c) 120.82 meters
(d) 120.80 meters
6. What is the thread consumption of men’s dress shirt with 301 class seam of 6 meters
and 401 class seam of 2 meters.
(a) 29.60 meters
(b) 28.60 meters
(c) 26.60 meters
(d) 25.60 meters
7. In a T-shirt, class 602 stitch is used extensively. If 3.5 meters of the 4 thread chain
stitch is used, what is the thread consumption?
(a) 100.50 meters
(b) 90.60 meters
(c) 96.25 meters
(d) 95. 65 meters
8. In a dress extensive embroidery is used. The total number of stitches is 6000 and the
SPI is 14. What is the class of stitch? And how much thread is consumed?
Ans.: Class of stitch used in embroidery is 101. Thread consumption is 41.91
meters
9. There are two types of thread used in men’s jacket for class 301 and class 512.
Lockstitch seams measure 6.5 meters and overlock stitch length is 3 meters. What is
the quantity used for each class of stitch?
Ans.: For class 301 thread consumption is 17.88 meters and class 512 it is
59.40 meters
10. In a skirt lockstitch seams are used for 3 yards and overlock stitch length is 2 meters.
What is the total thread consumed in meters?
(a) 39.33 meters
(b) 38.33 meters
(c) 37.39 meters
(d) 39.33 meters
11. A ladies pant has 2 meters of lockstitch seams and 0.75 meters of three thread
overlock seams. Calculate total thread consumption for 5000 pants?
(a) 82225 meters
(b) 85250 meters
(c) 82520 meters
(d) 80250 meters
12. If the actual consumption is 350 meters thread used in lockstitch of a shirt and
estimated consumptions is 125.5 meters, which is greater and by how much?
Ans.: Actual consumption is exceeds by 6.25 meters
13. A merchandiser ordered for 198 boxes of 1000 meter tubes of thread for a skirt
production. Each box contains 10 tubes. The lockstitch seams of the garment measure
125 meters and 2 thread chain of stitch seam measures 25.75 meters. The order
quantity of skirts is 4000. Will there be excess thread or shortage of thread?
Ans.: There will be a shortage of thread by 18,150 meters
14. A top and skirt set has 25.75 meters of class 301 stitch and 15.00 meters of class 401
stitch. Order quantity of the set is 3200 units. How much thread must be ordered for
production?
(a) 516000
(b) 517000
(c) 520000
(d) 518000
15. The order quantity of a dress is 10,000 units and each dress has 20.00 meters DTM
thread of stitch class 301and 5 meters of white thread of stitch class 512. How many
boxes of thread must be ordered each containing 10 cones of 5,000 meters?
Ans.: DTM thread of 11 boxes and white thread of 20 boxes
16. Merchandiser received an order for 20,000 men’s shirts. Each shirt has 10 meters of
lockstitch and 15meters of 3-thread overlock. How many cones of 5000 meters must
be ordered?
i. 1060
ii. 1034
iii. 1050
iv. 1054
17. An outerwear jacket has 3 colours of fabric to be sewn with dyed to match thread.
Each colour seams are 8 meters lockstitch. The jacket has a lining in navy blue fabric
to be stitched in matching colour thread. The lining seams stitched in lockstitch of 3
meters. Overlock seams inside jacket measure 8 meters in 3 matching colours and 2
meters of lining overlock in navy blue thread. Calculate the jacket thread by colour
for shell and lining.
Ans.: Thread requirement by colour for shell 435.60 meters and lining thread
requirement is 39.05 meters
18. A formal trouser has 12 meters of lockstitch seams and 5 meters of 4 thread overlock
seams. If the order quantity is 24,000 trousers, how much thread must be ordered in
cones of 10000 meters?
a. 320 cones
b. 317 cones
c. 318 cones
d. 322 cones
19. A dress order is received in 3 colours. The length of lockstitch seams in dress is 14
meters and four thread overlock stitch length is 6 meters. In addition a decorative 2
thread chain stitch of 3 meters is used. If the order quantity is 4,000 dresses per
colours, how many cones of 5000 meters must be ordered in each colour?
i. 124 cones
ii. 130 cones
iii. 125 cones
iv. 126 cones
20. A shirt order is received in 4 colours. Lockstitch seams in the shirt measure 6 meters,
and 2 thread chain stitch seams measure 2 meters. What is the consumption per type
of seam per colour per shirt?
Ans.: Lockstitch consumption is 16.50 meters and chain stitch consumption
is 12.10 meters